Fill-through-the-top package and method and apparatus for making the same

ABSTRACT

A fill-through-the-top reclosable package includes first and second opposing body panels joined to each other along a pair of sides and a bottom bridging the pair of sides. The package is provided with a reclosable fastener extending along a package top disposed opposite the bottom. The fastener includes first and second opposing tracks. The first track includes a male profile, while the second track includes a female profile adapted to releasably interlock with the male profile. To provide tamper evidence, the first and second tracks may be joined to each other along an area of weakness. When making the package, the first track is first attached to the first panel, the package is filled with a product via a fill opening between the second track and the second panel, and then the second track is attached to the second panel.

RELATED APPLICATION

This application is a divisional of U.S. application Ser. No.09/373,212, filed Aug. 12, 1999, now issued as U.S. Pat. No. 6,071,011on Jun. 6, 2000.

FIELD OF THE INVENTION

The present invention generally relates to packages to be filled with aproduct on a form, fill, and seal machine and, more particularly, to areclosable package filled through its top on a form, fill, and sealmachine.

BACKGROUND OF THE INVENTION

A typical reclosable package includes first and second opposing panelsjoined to each other along a pair of sides and a bottom bridging thepair of sides. A reclosable fastener extends along a package topdisposed opposite the bottom. The fastener generally includes first andsecond opposing tracks. The first track includes a male profile, whilethe second track includes a female profile adapted to releasablyinterlock with the male profile. The first and second tracks arethermally fused to, or integrally formed with, the respective first andsecond panels. To open and close the fastener, the package may beprovided with a slider mounted to the fastener.

If reclosable packages of the foregoing type are to be prepackaged witha product and then sold in a store, the packages are typically preparedon a horizontal or vertical form, fill, and seal machine. In the form,fill, and seal machine, the package is first formed into the shape of apouch having a fill opening at either the top or the bottom. If the fillopening is disposed at the bottom, then the top is sealed prior tofilling the package. Similarly, if the fill opening is disposed at thetop, then the bottom is sealed prior to filling the package. Next, thepackage filled with the product via the fill opening. Finally, the fillopening is sealed shut to fully enclose the product within the package.If the product delivered to the package includes food, then the fillopening is typically provided at the package bottom and a tamper-evidentfeature is provided along the top. The tamper-evident feature indicatesto a consumer whether or not the package has been tampered with prior topurchase.

Some reclosable packages include a gusset along the bottom which expandsin response to filling the package with a product. The gusset isadvantageous because it increases the volume of product that can becontained in the package and, when the gusset expands, it allows thepackage to stand up on a store shelf. The stand-up package obviates theuse of additional features such as headers with holes for hanging thepackage from a hook or post. The bottom gusset, however, makes it lesspractical to provide a fill opening at the bottom because most of theproduct resides in the gusset.

SUMMARY OF THE INVENTION

In accordance with one aspect of the present invention, afill-through-the-top reclosable package includes first and secondopposing body panels joined to each other along a pair of sides and abottom bridging the pair of sides. The bottom optionally includes agusset. The package is provided with a reclosable fastener extendingalong a package top disposed opposite the bottom. The fastener includesfirst and second opposing tracks. The first track includes a maleprofile, while the second track includes a female profile adapted toreleasably interlock with the male profile. To provide tamper evidence,the first and second tracks are joined to each other along an area ofweakness. The first and second tracks are optionally provided withrespective first and second fins joined to each other along theaforementioned area of weakness to effectively create a single fincomprised of the first and second fins. To open and close the fastener,the package is optionally provided with a slider mounted to thefastener.

The package is convertible between a pre-filled condition and apost-filled condition. In the pre-filled condition, the first track isconnected to the first panel, but the second track is only connected tothe second panel along the sides thereby creating a fill opening betweenthe second track and the second panel in a region between the sides.After the package is filled with a product via the fill opening, thepackage is converted to the post-filled condition. In the post-filledcondition, the second track is connected to the second panel to seal thefill opening.

In accordance with another aspect of the present invention, a method ofmaking a reclosable package includes the following sequence of steps:

(a) supplying a web of plastic material;

(b) supplying a reclosable fastener including first and second opposingtracks, the first track including a male profile, the second trackincluding a female profile adapted to releasably interlock with the maleprofile, the first and second tracks being joined to each other along anarea of weakness;

(c) folding the web to provide first and second opposing panels;

(d) attaching the first track to the first panel;

(e) sealing the web such that the first and second panels are joined toeach other along a pair of sides and a bottom bridging the pair ofsides;

(f) filling the package with a product via a fill opening between thesecond track and the second panel; and

(g) attaching the second track to the second panel to seal the fillopening.

In accordance with yet another aspect of the present invention, anothermethod of making a reclosable package includes the following sequence ofsteps:

(a) supplying a web of plastic material in a longitudinal direction;

(b) supplying a reclosable fastener including first and second opposingtracks, the first track including a male profile, the second trackincluding a female profile adapted to releasably interlock with the maleprofile;

(c) folding the web along one or more longitudinal folds to providefirst and second opposing panels, the longitudinal folds creating abottom of the package;

(d) attaching the first track to the first panel;

(e) sealing the web along a pair of sides, the bottom bridging the pairof sides;

(f) filling the package with a product via a fill opening between thesecond track and the second panel; and

(g) attaching the second track to the second panel to seal the fillopening.

In accordance with a further aspect of the present invention, there isprovided an apparatus for performing the above methods.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and advantages of the invention will become apparent uponreading the following detailed description and upon reference to thedrawings in which:

FIG. 1 is an isometric view of a reclosable plastic bag in a pre-filledcondition embodying the present invention;

FIG. 2 is a sectional view taken generally along line 2—2 in FIG. 1;

FIG. 3 is an isometric view of the reclosable plastic bag in apost-filled condition;

FIG. 4 is a sectional view taken generally along line 4—4 in FIG. 3;

FIGS. 5a and 5 b are a diagrammatic representation of a method andapparatus for making and filling the reclosable plastic bag;

FIG. 6 is a diagrammatic representation of a method and apparatus forsealing the reclosable plastic bag;

FIG. 7 is a sectional view taken generally along line 7—7 in FIG. 6;

FIG. 8 is a sectional view taken generally along line 8—8 in FIG. 6; and

FIG. 9 is a sectional view taken generally along line 9—9 in FIG. 6.

While the invention is susceptible to various modifications andalternative forms, a specific embodiment thereof has been shown by wayof example in the drawings and will herein be described in detail. Itshould be understood, however, that it is not intended to limit theinvention to the particular forms disclosed, but on the contrary, theintention is to cover all modifications, equivalents, and alternativesfalling within the spirit and scope of the invention as defined by theappended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning now to the drawings, FIGS. 1 and 3 depict a fill-through-the-topreclosable package 10, and FIGS. 2 and 4 depict a top portion of thepackage 10. Referring to FIGS. 1 through 4, the package 10 includesfirst and second opposing body panels 12 and 14 joined to each otheralong a pair of sides 16 and a bottom 20 bridging the pair of sides 16.The bottom 20 optionally includes a gusset 22.

The package 10 is provided with a reclosable fastener 23 extending alonga package top disposed opposite the gusseted bottom 20. The fastener 23includes first and second opposing tracks 24 and 26. The first track 24includes a rib-type male profile 28 and a first fin 30 extendingdownward from the male profile 28, while the second track 26 includes agroove-type female profile 32 and a second fin 34 extending downwardfrom the female profile 32. The male and female profiles 28 and 32 areadapted to interlock with each other. The first track 24 includes aplurality of narrow first sealant ribs 36 on an outer surface of thefirst fin 30 to facilitate connecting the first fin 30 to the firstpanel 12, and the second track 26 includes a plurality of narrow secondsealant ribs 38 on an outer surface of the second fin 34 to facilitateconnecting the second fin 34 to the second panel 14. To provide tamperevidence, lowermost ends of the first and second fins 30 and 34 arejoined to each other along a line of weakness 40 to effectively create asingle fin comprised of the first and second fins 30 and 34. The line ofweakness 40 may be a scored line, a perforated line, a thinned die line,or a tear strip. In an alternative embodiment, the first and secondtracks 24 and 26 do not include the respective depending fins 30 and 34,and tamper evidence is provided by joining the lowermost ends of theprofiles 28 and 34 instead of the lowermost ends of the fins.

To open and close the fastener 23, the package 10 is optionally providedwith a slider 42 mounted to the fastener 23. The slider 42 disengagesthe profiles 28 and 32 in response to movement along the fastener 23 inan opening direction and engages the profiles 28 and 32 in response tomovement along the fastener 23 in a closing direction. To accommodatethe slider 42 and make it difficult to open the fastener 23 withoutusing the slider 42, the fastener 23 is preferably free of pull flangesextending upwardly from the male and female profiles 28 and 32. To stopmovement of the slider 42 near the sides 16 of the package 10 andthereby prevent the slider 42 from sliding off the end of the fastener23, a pair of end terminations 44 and 46 are mounted to the fastener 23near the respective sides 16 of the package.10. The end termination 44stops movement of the slider 42 in the opening direction, while the endtermination 46 stops movement of the slider 42 in the closing direction.The end terminations 44 and 46 may be a separate element attached to thefastener 23, as shown in FIGS. 1 and 3, or may be integrally formed withthe fastener 23. Examples of end terminations are disclosed in U.S. Pat.No. 5,088,971 to Herrington, U.S. Pat. No. 5,131,121 to Herrington etal., U.S. Pat. No. 5,161,286 to Herrington et al., U.S. Pat. No.5,405,478 to Richardson et al., U.S. Pat. No. 5,442,837 to Morgan, U.S.Pat. No. 5,448,807 to Herrington, U.S. Pat. No. 5,482,375 to Richardsonet al., and U.S. Pat. No. 5,924,173 to Dobreski et al., which areincorporated herein by reference in their entireties.

The package 10 is convertible between a pre-filled condition and apost-filled condition. In the pre-filled condition shown in FIGS. 1 and2, the first fin 30 is connected to the first panel 12, but the secondfin 34 is not connected to the second panel 14, except along the sides16, thereby creating a fill opening between the second fin 34 and thesecond panel 14. After the package 10 is filled with a product via thefill opening, the package 10 is converted to the post-filled conditionshown in FIGS. 3 and 4. In the post-filled condition, the second fin 34is connected to the second panel 14 to seal the fill opening. If thebottom 20 includes the gusset 22, the gusset 22 expands in response tofilling the package 10 with the product. The gusset 22 is advantageousbecause it increases the volume of product that can be contained in thepackage 10 and, when the gusset 22 expands, it allows the package 10 tostand up on a store shelf 48. The stand-up package 10 obviates the useof additional features such as headers with holes for hanging thepackage from a hook or post.

In accordance with another aspect of the present invention, there isprovided a method and apparatus for making and filling the reclosablepackage 10. The method and apparatus are illustrated in FIGS. 5a-b, 6,7, 8, and 9. Referring first to FIGS. 5a and 5 b, a core 50 supplies aweb 52 of plastic material. A folder 53 folds the web 52 to providefirst and second opposing panels 12 and 14 joined along a bottom 20having one or more fold lines. The folder 53 optionally includes agusset point 54 that creates a gusset 22. The folded web 52 is conveyedbetween a pair of rollers 56 that bring the first and second panels 12and 14 is close proximity to each other. A spool 58 supplies areclosable fastener 23 having the structure discussed above. Thefastener 23 is fed between the upper portions of the first and secondpanels 12 and 14.

A sealer 60 seals the first fin 30 (see FIGS. 1 and 2) to the firstpanel 12 in the machine direction, i.e., the direction of movement ofthe web 52. The sealer 60 may be a stationary convective (hot air)sealer that does not contact the web 52, a reciprocating heated barsealer that intermittently contacts the web 52, or a band sealercomprising a heated band that moves with the web 52 until the seal ismade. The first sealant ribs 36 (see FIGS. 1 and 2) on the outer surfaceof the first fin 30 facilitate this attachment between the first fin 30and the first panel 12. At this time, the second fin 34 remainsdisconnected from the second panel 14. Another reciprocating heated barsealer 62 seals the first and second panels 12 and 14 to each other inthe transverse direction. The side seals 16 are generated by the sealer62 at bag width distances apart to create individual packages 10. If thebottom 20 includes a gusset 22, a heated bar sealer 64 creates a pair ofangle seals 66 along the gusset 22 on opposite sides of each side seal16. The first and second panels 12 and 14 are attached to each other atthe angle seals 66.

If the packages 10 are provided with respective sliders 42, the sliders42 are mounted to the fastener 23 at bag width distances apart eitherbefore the fastener 23 is attached to the web 52 or after the fastener23 is attached to the web 52. FIG. 5b depicts the sliders 42 as beinginstalled after the fastener 23 is attached to the web 52 and after theformation of the side seals 16. To stop movement of the slider 42 nearthe sides 16 of each package 10, a pair of end terminations 44 and 46are mounted to the fastener 23 on opposite sides of each side seal 16.

The sliders 42 may be installed using various techniques. For example,the slider 42 may have hinged wings that fold and snap permanently inplace to attach the slider 42 to the fastener 23. Further detailsconcerning such a hinged slider may be obtained from U.S. Pat. Nos.5,010,627, 5,063,644, and 5,070,583 to Herrington, which areincorporated herein by reference in their entireties. In an alternativeembodiments the slider 42 may have a pair of side walls that aretemporarily flexed away from each other as the slider 42 is mounted onthe fastener 23 and then returned to their original position after theslider 42 is mounted. In another alternative embodiment, prior to theformation of the side seals, the fastener 23 is cut apart at a locationwhere a side seal is to be generated, the ends formed by the cutter aremoved laterally relative to each other to expose the ends, and theslider 42 is threaded onto one of the exposed ends. Further detailsconcerning this technique of inserting a slider through a split fastenermay be obtained from U.S. Pat. No. 5,431,760 to Donovan, which isincorporated herein by reference in its entirety. In yet anotheralternative embodiment, prior to the formation of the side seals, thefastener 23 is notched at a location where a side seal is to begenerated and the slider 42 is threaded onto the fastener 23 via thenotch. The notch is sized to accommodate the slider 42. Further detailsconcerning this technique of inserting a slider onto a notched fastenermay be obtained from U.S. application Ser. No. 09/307,937 to Provan etal. entitled “Zipper and Zipper Arrangements and Methods ofManufacturing the Same”, filed May 10, 1999, and incorporated herein byreference in its entirety.

After forming the side seals 16 and installing such optional componentsas a slider 42 and end terminations 44 and 46, a cutter 68 separates thepackages 10 from each other at the side seals 16. Each package 10 isthen placed beneath a fill tube 70 having a spout that is inserted intoa fill opening between the second fin 34 and the second panel 14 (seeFIGS. 1 and 2). The fill tube 70 conveys a predetermined amount ofproduct to the interior of the package 10. The gusset 22 expands inresponse to filling the package 10 with the product.

FIG. 6 illustrates a method and apparatus for sealing the filledpackages 10 so that they are ready for shipment to and display at astore. The apparatus includes a pair of spaced, profiled guides 72, apair of moving members 74, a reciprocating heated bar sealer 76, and astationary backing plate 82. The profiled guides 72 are shaped incross-section to support each package by either the fastener 23, theslider 42, and/or the end terminations 44 and 46. As best shown in FIG.7, the illustrated guides 72 include respective first steps 78 forengaging the respective lower shoulders of the slider 42 and respectivesecond steps 80 for engaging the lower sides of the end terminations 44and 46. The opposing inner vertical faces of the guides 72 below thesecond steps 80 are spaced sufficiently apart to allow the fins 30 and34 to fit therebetween, but sufficiently close to minimize the amount ofair in the package head space above the product in the filled package.Each filled package 10 may be manually placed between the guides 72 orautomatically fed into the guides 72 by conventional conveyingequipment. The guides 72 are preferably made of a low-friction, rigidmaterial such as hard anodized aluminum or ultra high densitypolyethylene.

The moving members 74 are disposed on opposite sides of the package 10beneath the respective guides 72. The moving members 74 continuously orintermittently convey the packages 10 supported by the guides 72 to thesealer 76. Each moving member 74 is preferably a Teflon-coatedglass-cloth belt encompassing a pair of spaced pulleys. As shown inFIGS. 6 and 8, the reciprocating heated bar sealer 76 is disposed withinone of the conveyor belts, while the backing plate 82 is disposed withinthe other of the conveyor belts. When a package 10 is disposed betweenthe sealer 76 and the backing plate 82, the sealer 76 presses thepackage 10 against the backing plate 82 (with the belts disposedtherebetween) to attach the second fin 34 to the second panel 14 in theregion between the sides 16, thereby sealing the fill opening of thefilled package 10 (see FIG. 8). The backing plate 82 is optionallycooled with chilled water or cool air as such pressure is applied by thesealer 76. Additional cooling bars are optionally located within themoving members 74 downstream from the sealer 76 and the backing plate82. Instead of the heated bar sealer 76, the apparatus for sealing thefilled packages may include a heated band of metal, such as steel,lining the inner surface of the belt of each moving member 74 and movingwith the belt. The heated bands inside the respective belts seal thesecond fin 34 to the second panel 14 as the belts convey the associatedpackage 10 through the guides 72. Once the fill opening is sealed, thepackage 10 is ready for shipment to and display at a store. The fullysealed package 10 is shown in FIG. 9.

The package 10 may be composed of various plastic polymers, copolymers,coextrusions and/or laminations. The panels 12 and 14 are preferablycomprised of mono-layer or multi-layer combinations of: polyethylene(high, medium, low, linear low, and/or ultra low density polymersincluding metallocene); polypropylene (oriented and/or biaxiallyoriented); ethylene vinyl acetate; nylon (oriented and/or biaxiallyoriented); polyethylene terephthalate (oriented and/or biaxiallyoriented); polyvinyl chloride; ethylene vinyl alcohol (EVOH);polyvinylidene chloride (PVDC); polyvinyl alcohol (PVOH); polystyrene;foil and/or metalization; and paper. The slider 42 and end terminations44 and 46 are preferably comprised of mono-material, blends, alloys,and/or co-polymers of: polyethylene (high, medium, low, linear low,and/or ultra low density polymers); polypropylene (oriented and/orbiaxially oriented); ethylene vinyl acetate; nylon (oriented and/orbiaxially oriented); thermoplastic polyesters; polycarbonate; acrylics;and/or polystyrene. The profiles 12 and 14 and the fins 30 and 34 arepreferably comprised of mono-layer, blends, alloys, coextrusions,laminations and/or coatings of: polyethylene (high, medium, low, linearlow, and/or ultra low density polymers including metallocene);polypropylene (oriented and/or biaxially oriented); ethylene vinylacetate; nylon (oriented and/or biaxially oriented); polyethyleneterephthalate (oriented and/or biaxially oriented); polyvinyl chloride;ethylene vinyl alcohol (EVOH); polyvinylidene chloride (PVDC); polyvinylalcohol (PVOH); polystyrene; foil and/or metalization; and paper. Thesealant ribs 36 and 38 are preferably comprised of mono-material,blends, and/or coextrusions of: polyethylene (low, linear low, and/orultra low density polymers including metallocene); ethylene vinylacetate, adhesive or low melting temperature sealant.

While the present invention has been described with reference to one ormore particular embodiments, those skilled in the art will recognizethat many changes may be made thereto without departing from the spiritand scope of the present invention. Each of these embodiments andobvious variations thereof is contemplated as falling within the spiritand scope of the claimed invention, which is set forth in the followingclaims.

What is claimed is:
 1. A method of filling a package, made from acontinuous web of material comprising: providing a plurality ofinterconnected packages made from said web, each package including firstand second opposing body panels joined along a pair of sides and abottom bridging the sides, the package including a fastener attached tothe first body panel along a mouth portion of the package disposedopposite the bottom, the fastener initially being at least partiallyunattached to the second body panel while the fastener is attached tothe first body panel; separating each package from said plurality ofinterconnected packages; filling the separated package with a productvia a fill opening between the fastener and the second body panel; andattaching the fastener to the second body panel of the filled package toseal the fill opening.
 2. The method of claim 1, wherein the fastenerincludes first and second interlocking profiles and first and secondfins extending from the respective profiles, the first and second finsbeing joined along the breakable area of weakness, the first fin beingattached to the first body panel, the second fin being at leastpartially unattached to the second body panel while the fastener isattached to the first body panel.
 3. The method of claim 2, wherein thefill opening in the step of filling the package is between the secondfin and the second body panel.
 4. The method of claim 3, wherein thestep of attaching the fastener to the second body panel includesattaching the second fin to the second body panel.
 5. The method ofclaim 1 further including the step of sealing said first and second bodypanels above said fastener.
 6. A method of making and filling a package,comprising: providing a package including first and second opposing bodypanels; attaching a fastener to the first body panel along a mouthportion of the package; attaching said first and second panels to eachother to form a pair of sides and a bottom bridging the sides oppositethe fastener; filling the package with a product via a fill openingbetween the fastener and the second body panel; and attaching thefastener to the second body panel to seal the fill opening.
 7. Themethod of claim 6, wherein the fastener includes first and secondinterlocking profiles and first and second fins extending from therespective profiles, the fill opening in the step of filling the packagebeing between the second fin and the second body panel, wherein the stepof attaching the fastener to the first body panel includes attaching thefirst fin to the first body panel, and wherein the step of attaching thefastener to the second body panel includes attaching the second fin tothe second body panel.
 8. The method of claim 7, wherein the first andsecond fins are joined to each other along the breakable area ofweakness.
 9. A method of making and filling packages, comprising:providing a plastic web and a fastener in a longitudinal direction;folding the web to provide first and second opposing panels joined alonga longitudinal bottom; attaching the fastener to an inner surface of thefirst panel near a longitudinal edge thereof opposite the longitudinalbottom; sealing the first and second panels to each other at spacedseals transverse to the longitudinal direction to form the packages;filling each package with a product via a fill opening between thefastener and the second panel; and attaching the fastener to an innersurface of the second panel to seal the fill opening.
 10. The method ofclaim 9, wherein said bottom includes a gusset.
 11. A method of fillinga package made from a continuous web of material, comprising: providinga plurality of interconnected packages made from said web, each packageincluding two panels defining a mouth portion and a reclosable fastenerthat is useful for opening and closing said mouth portion after saidpackage is filled, said fastener having a final attachment position onsaid two panels and being attached to said two panels along only aportion of said final attachment position so as to define an unattachedsegment and an attached segment of said fastener, said unattachedsegment and the adjacent one of said two panels define a fill openingtherebetween; filling said package with a product through said fillopening; and separating each package from said plurality ofinterconnected packages; attaching said unattached segment of saidfastener to said panels along the entirety of said final attachmentposition.
 12. The method of claim 11, wherein said package includes abottom with a gusset.
 13. The method of claim 11, wherein said fastenerincludes a first interlocking profile with a first fin and secondinterlocking profile with a second fin.
 14. The method of claim 13,wherein said first and second fins are joined along a breakable area ofweakness.
 15. The method of claim 13, wherein, during said providingstep, said first fin is attached to a first one of said two panels alongsaid final attachment position and said second fin is at least partiallyunattached to a second one of said two panels along said finalattachment position, said second fin and said second panel defining saidfill opening.
 16. The method of claim 14, wherein said second fin isentirely unattached to said second one of said two body panels alongsaid final attachment position.